Power control system for DC-DC converter and inverter pre-charging and shutdown

1. A power control system for a propulsion system of a vehicle, comprising:

an energy storage system including a precharge circuit and one or more battery packs;

a DC-DC converter connected to the energy storage system and including a first capacitor, a first plurality of power switches and an inductor;

a power inverter module connected to the DC-DC converter and including a second capacitor and a second plurality of power switches; and

a controller configured to:

pre-charge the first capacitor of the DC-DC converter and the second capacitor of the power inverter module; and

control operating modes of the DC-DC converter and the power inverter module,

wherein the controller is configured to at least one of

after pre-charging the first capacitor of the DC-DC converter, control an output voltage of the DC-DC converter to ramp up voltage across the second capacitor of the power inverter module to pre-charge the second capacitor, and

close a bidirectional bypass switch and concurrently pre-charge the first capacitor and the second capacitor, the bidirectional bypass switch being connected between the power inverter module and the energy storage system, and

wherein the controller is configured to

when stopping the propulsion system, ramp down the output voltage of the DC-DC converter to the voltage less than a first predetermined threshold,

when the output voltage of the DC-DC converter is less than the first predetermined threshold, transition the power inverter module from a run mode to a stop mode and the DC-DC converter from a run mode to a standby mode, and

disconnect the energy storage system and, when an input voltage of the DC-DC converter is less than a second predetermined threshold, transition the propulsion system from an active mode to a stop mode.

2. The power control system of claim 1 , wherein the controller is configured to, after pre-charging the first capacitor of the DC-DC converter, control the output voltage of the DC-DC converter to ramp up voltage across the second capacitor of the power inverter module to pre-charge the second capacitor.

3. The power control system of claim 1 , wherein the controller is configured to, after pre-charging the first capacitor of the DC-DC converter, transition the DC-DC converter from the standby mode to the run mode and control the output voltage of the DC-DC converter to ramp up the voltage across the second capacitor of the power inverter module to pre-charge the second capacitor.

4. The power control system of claim 1 , further comprising the bidirectional bypass switch connected between the power inverter module and the energy storage system.

5. The power control system of claim 4 , wherein the controller is configured to close the bidirectional bypass switch and concurrently pre-charge the first capacitor and the second capacitor.

6. The power control system of claim 5 , wherein, in response to a difference between a voltage across a precharge resistor in the energy storage system and a voltage of the first capacitor being less than the first predetermined threshold, the controller selectively transitions the energy storage system to a regular mode and opens the bidirectional bypass switch.

7. The power control system of claim 6 , wherein:

the controller determines a difference between the output voltage of the DC-DC converter and an input voltage of the power inverter module;

while the difference is greater than the second predetermined threshold, the controller incrementally adjusts the output voltage of the DC-DC converter by a delta voltage; and

when the difference is less than the second predetermined threshold, the controller transitions the power inverter module from a stop mode to a run mode and the propulsion system from an off mode to the active mode.

8. The power control system of claim 4 , wherein when the propulsion system is in the active mode, the bidirectional bypass switch is closed and the DC-DC converter is in standby mode, the controller is configured to stop the propulsion system by:

disconnecting the energy storage system; and

transitioning the power inverter module from a run mode to a stop mode when output voltages of the DC-DC converter and the power inverter module are less than the first predetermined threshold.

9. The power control system of claim 8 , wherein when voltages across the first capacitor and the second capacitor are less than the second predetermined threshold, the controller transitions the propulsion system from the active mode to an off mode.

10. A power control system for a propulsion system of a vehicle, comprising:

an energy storage system including a precharge circuit and one or more battery packs;

a DC-DC converter connected to the energy storage system and including a first capacitor, a first plurality of power switches and an inductor;

a power inverter module connected to the DC-DC converter and including a second capacitor and a second plurality of power switches; and

a controller configured to

pre-charge the first capacitor of the DC-DC converter and the second capacitor of the power inverter module, and

control operating modes of the DC-DC converter and the power inverter module,

wherein at least one of

ii) when a difference between an input voltage of the power inverter module and a predetermined target voltage is less than a predetermined threshold, the controller transitions the power inverter module from a stop mode to a run mode and the propulsion system from a stop mode to an active mode, and

ii) the power control system further comprises a bidirectional bypass switch connected between the power inverter module and the energy storage system, and when a) the propulsion system is in the active mode, b) the bidirectional bypass switch is closed and c) the DC-DC converter is in standby mode, the bidirectional bypass switch being connected between the power inverter module and the energy storage system, and the controller being configured to stop the propulsion system by

disconnecting the energy storage system, and

transitioning the power inverter module from a run mode to a stop mode when output voltages of the DC-DC converter and the power inverter module are less than a first predetermined threshold.

11. A power control system for a propulsion system of a vehicle, comprising:

an energy storage system including a precharge circuit and one or more battery packs;

a DC-DC converter connected to the energy storage system and including a first capacitor, a first plurality of power switches and an inductor;

a power inverter module connected to the DC-DC converter and including a second capacitor and a second plurality of power switches; and

a controller configured to:

pre-charge the first capacitor of the DC-DC converter;

transition the DC-DC converter from a standby mode to a run mode; and

determine a difference between an output voltage of the DC-DC converter and an input voltage of the power inverter module:

while the difference is greater than a first predetermined threshold, ramp the output voltage of the DC-DC converter; and

when the difference is less than the first predetermined threshold, transition the power inverter module from a stop mode to a run mode and the propulsion system from an off mode to an active mode.

12. The power control system of claim 11 , wherein when stopping the propulsion system, the controller is configured to:

selectively ramp down the output voltage of the DC-DC converter;

when the output voltage of the DC-DC converter is less than a second predetermined threshold, transition the power inverter module from a run mode to a stop mode and the DC-DC converter from a run mode to a standby mode;

disconnect the energy storage system; and

when an input voltage of the DC-DC converter is less than a third predetermined threshold, transition the propulsion system from the active mode to a stop mode.

13. A power control system for a propulsion system of a vehicle, comprising:

an energy storage system including a precharge circuit and one or more battery packs;

a DC-DC converter connected to the energy storage system and including a first capacitor, a first plurality of power switches, an inductor and a bidirectional bypass switch;

a power inverter module connected to the DC-DC converter and including a second capacitor and a second plurality of power switches,

wherein the bidirectional bypass switch is connected between the power inverter module and the energy storage system; and

a controller configured to:

close the bidirectional bypass switch and concurrently pre-charge the first capacitor and the second capacitor; and

after pre-charging the first capacitor and the second capacitor, transition a mode of the DC-DC converter from a standby mode to a run mode.

14. The power control system of claim 13 , wherein the controller is configured to calculate a difference between an output voltage of the DC-DC converter and an input voltage of the power inverter module.

15. The power control system of claim 14 , wherein:

when the difference is greater than a predetermined threshold, the controller is configured to incrementally adjust the output voltage of the DC-DC converter by a delta voltage; and

when the difference is less than the predetermined threshold, the controller is configured to transition the power inverter module from a stop mode to a run mode and the propulsion system from an off mode to an active mode.

16. The power control system of claim 13 , wherein when the propulsion system is in an active mode, the bidirectional bypass switch is closed and the DC-DC converter is in standby mode, the controller is configured to stop the propulsion system by:

disconnecting the energy storage system; and

transitioning the power inverter module from a run mode to a stop mode when an output voltage of the DC-DC converter and an input voltage of the power inverter module are less than a first predetermined threshold.

17. The power control system of claim 16 , wherein when voltages of the first capacitor and the second capacitor are less than a second predetermined threshold, the controller transitions the propulsion system from the active mode to an off mode.